Die Casting Methods
Die Casting Methods
Hot Chamber High Pressure Die Casting:
The cylinder and piston, used to quickly inject the molten metal into the die under pressure, are immersed in the molten metal. Used for finely detailed, thin castings in zinc and some magnesium alloys.
Cold Chamber High Pressure Die Casting:
The molten metal is poured into the injection cylinder and then quickly injected into the die under pressure. Used for finely detailed thin castings in aluminium, magnesium and brass.
Gravity or Permanent Mould Die Casting:
The molten metal is gently poured into the die cavity under the force of gravity. Used for all alloys, particularly large aluminium castings and those requiring sand cores for complex internal detail, such as automotive cylinder heads.
Low Pressure Die Casting:
Molten metal is introduced into a die from below by means of a low pressure gas applied to the metal in a sealed furnace. Used for high integrity aluminium castings such as automotive wheels.
Squeeze Casting:
Molten metal is introduced very slowly and smoothly into a die where high pressure is maintained until after the casting is solid. Used for high integrity, high strength aluminium castings such as automotive brake callipers.
Automation and Quality Control:
Modern die casters use a number of sophisticated methods to automate the die casting process and provide continuous quality control. Automated systems can be used to lubricate dies, ladle metal into cold chamber machines and integrate other functions, such as quenching and trimming castings. Microprocessors obtain metal velocity, shot rod position, hydraulic pressure and other data that is used to adjust the die casting machine process, assuring consistent castings shot after shot. These process control systems also collect machine performance data for statistical analysis in quality control.
Die Casting Design:
Die casting is one of the fastest and most cost-effective methods for producing a wide range of components. However, to achieve maximum benefits from this process, it is critical that designers collaborate with the die caster at an early stage of the product design and development. Consulting with the die caster during the design phase will help resolve issues affecting tooling and production, while identifying the various trade-offs that could affect overall costs.
For instance, parts having external undercuts or projections on sidewalls often require dies with slides. Slides increase the cost of the tooling, but may result in reduced metal use, uniform casting wall thickness or other advantages. These savings may offset the cost of tooling, depending upon the production quantities, providing overall economies.
Many sources are available for information on die casting design, including textbooks, technical papers, trade journals and professional associations. While this section is not intended to provide a comprehensive review of all the factors involving die casting design, it will highlight some of the primary considerations. Additional sources of information are listed in the “Resources” section of this brochure.
We have a network of hundreds of reputable casting foundries in China, and offer you the most efficient way to source low cost casting products and parts from China. We manage the total process from quotation, to manufacturing, to quality checking, to shipping.
Business Scope: Sand Casting, Lost Wax Casting, Die Casting, Stainless Steel Casting, Iron Casting, Casting and Machining, Low Pressure Casting
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